System and method for achieving position detection integrity in an independent cart system

A method for detecting integrity of a position for a mover in an independent cart system, wherein a magnet array is mounted on the mover and the independent cart system includes a track having a plurality of track segments, the method comprising the steps of:

• receiving a plurality of first position feedback signals at a first processing core for a track segment, wherein each of the plurality of first position feedback signals is generated by a first position sensor mounted on the track segment and configured to detect the magnet array mounted on the mover;
• receiving a plurality of second position feedback signals at a second processing core for the track segment, wherein each of the plurality of second position feedback signals is generated by a second position sensor mounted on the track segment and configured to detect the magnet array mounted on the mover;
• generating a first value of the position of the mover along the track segment with the first processing core responsive to receiving the plurality of first position feedback signals;
• generating a second value of the position of the mover along the track segment with the second processing core responsive to receiving the plurality of second position feedback signals;
• and
• comparing the first value to the second value of the position of the mover with either the first processing core or the second processing core to verify operation of each of the first position sensors and the second position sensors.

A method for detecting integrity of a position for a mover in an independent cart system, wherein a magnet array is mounted on the mover and the independent cart system includes a track having a plurality of track segments, the method comprising the steps of:

• receiving a plurality of first position feedback signals at a first processing core for a track segment, wherein the plurality of first position feedback signals are generated by a plurality of first position sensors mounted on the track segment to detect the magnet array and the plurality of first position feedback signals includes paired sine wave and cosine wave signals;
• receiving a plurality of second position feedback signals at a second processing core for the track segment, wherein the plurality of second position feedback signals are generated by a plurality of second position sensors mounted on the track segment to detect the magnet array and the plurality of second position feedback signals includes paired sine wave and cosine wave signals;
• detecting a first edge of the mover by identifying either the first position feedback signals or the second position feedback signals having an inactive value at a first position along a track for the independent cart system and either the first position feedback signals or the second position adjacent the first position having an active value;
• detecting a second edge of the mover by identifying either the first position feedback signals or the second position feedback signals having an inactive value at a second position along a track for the independent cart system and either the first position feedback signals or the second position adjacent the second position having an active value;
• determining a length of the mover magnet array by either the first processing core or the second processing core as a function of the first position and the second position;
• and
• comparing the length of the mover magnet array determined by either the first processing core or the second processing core to a predefined length stored in a memory for either the first processing core or the second processing core to verify operation of the first position feedback signals and the second position feedback signals.